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0) Secret
Approved by Date
2007.9
Revision History
Date Version Description Author
Contents
1 Objective.........................................................................................................................................4
2 Applicability Scope.......................................................................................................................5
3 Competency Requirements for Maintenance Engineers.......................................................6
4 Operation Guide............................................................................................................................7
4.1 Preparations.......................................................................................................................................................7
4.2 Monthly (or Pre-Operation) Check....................................................................................................................7
4.3 Replacement of Consumables..........................................................................................................................13
4.4 Site Clean-Up and Maintenance Record..........................................................................................................18
1 Objective
This document describes the contents, operation modes, and precautions for routine
maintenance of diesel generators. Field maintenance engineers should comply with this guide
to supply the maintenance service for diesel generators.
2 Applicability Scope
4 Operation Guide
4.1 Preparations
No. Prepare Remarks
List of
Maintenance Tools for Diesel Generators.xls
Attachment:
To ensure that the fuel tank is clean, the fuel is sufficient, and the fuel pipe is in good
Objective
condition without block and leak.
Remove the sediment from the fuel tank through the drain valve at the bottom of the
tank.
Exception Fill the fuel tank (based on the fluid level gauge) and remove the overflowed diesel.
Handling
Replace any leaky or deformed fuel pipe with a new one.
Replace any rusty or blocked valve.
No smoking when filling the fuel tank.
You can replenish an external fuel tank but not a built-in one when the diesel
Precautions generator is running.
0# or –10# diesel is recommended. –10# diesel should be used when the ambient
temperature is below 0°C.
2. Engine Oil
3. Cooling System
Check Items
Ensure that the cooling water is sufficient.
Ensure that the water pipes are not leaky.
Do not open the filler on the water tank when the motor is hot or the pressure in the
water tank is high.
Do not check the water level till 15 minutes after the generator stops.
Precautions When you are filling water, air in the pipe cannot be removed at a time. Therefore,
you should fill water by stages. That is to say, wait for a moment after you fill some
water, and then fill water again. Repeat this process till you see the water level in the
inlet pipe.
4. Battery
Fill distilled water or purified water till the level exceeds the pole plate by 5 cm to 10
cm.
Exception Recharge the battery or check the charger in the case of low battery.
Handling
Polish the rusty wiring terminals by using a sand paper and then apply oil to the
wiring terminals. Fasten the connected wires if necessary.
Keep the battery away from any sparkle or flame, because the volatile gas of the
electrolyte is flammable.
Mis-connected polarities of a battery will damage the electrical system and the
battery.
Precautions
For an automatic start generator set, ensure that the start switch is off; otherwise, the
generator set might suddenly starts.
When removing a battery, disconnect the cathode and then the anode. When installing
a battery, connect the anode and then the cathode.
Objective To ensure that both the ATS and the ACDB work normally
Ensure that the power and signal cables connecting the diesel generator, ATS, and
ACDB are firmly connected.
Check Items Ensure that no electrical part is burned out.
Ensure that the diesel generator, ATS, and ACDB are well grounded.
Fasten any loosened cables.
Exception Replace any burned electrical parts.
Handling
Fasten all grounding cables.
Precautions Ensure that the diesel generator, ATS, and ACDB are well grounded
Objective To ensure that the protective cover and all screws and nuts are firmly fixed
Check Items Ensure that the protective cover and all screws and nuts are firmly fixed.
Exception
Fasten the loosened protective cover and all loosened screws and nuts.
Handling
8. Running Test
To ensure that the diesel generator can work normally after a basic check
To ensure that a diesel generator that has not worked for a long time (within two
Objective
weeks) can start in the case of emergency power supply
To ensure that the diesel generator, ATS, and ACDB can work normally
Check all parameters displayed on the control panel, including the revolutions,
voltage, current, frequency, oil pressure, and water temperature.
Ensure that the diesel generator is free of leakage (fuel, water, or air).
Check Items Ensure that all joints are firmly connected and the diesel generator does not vibrate
greatly.
Ensure that the ATS can automatically start and stop the diesel generator and that the
ATS can switch over power supply.
Shut down the diesel generator in the case of any exception.
Search for the reason immediately or turn to the technical support engineers in the
case of any exceptional parameter.
Check all pipes and connectors and replace or fasten any loosened connectors in the
Exception
case of leakage (oil, water, or air).
Handling
In the case of exceptional vibration of the diesel generator, find out and fasten the
loosened joints.
Locate the reason immediately or turn to the Technical Support if the ATS is in an
exceptional state.
Replace the engine oil after the first 50-hour operation, and then replace it once every
Frequency
250-hour operation (or quarterly).
Replace the oil filter after the first 50-hour operation, and then replace it once every
Frequency
250-hour operation (or quarterly).
Replace the original oil filter with a new one and ensure that no oil leakage exists
when the diesel generator is running.
Service Standards
After replacement of the oil filter, the oil pressure should be in the allowed range
when the diesel generator is running.
Replace engine oil when replacing the oil filter.
Use a new sealing ring when replacing an oil filter.
Precautions
Do not fasten the oil filter too tightly. If the oil filter is fastened too tightly, oil
leakage might exist because the sealing ring is deformed and damaged.
Frequency Replace the fuel filter once every 250-hour operation (or quarterly).
Operating
Procedure
After replacing the oil filter, run the diesel generator for 10 minutes. If air exists in
the fuel system, remove the air by using the fuel pump before starting the diesel
generator.
Replace the original fuel filter with a new one and ensure that no leakage exists when
the diesel generator is running.
Service Standards
After replacement of the fuel filter, the diesel generator works normally at a
satisfactory speed.
Replace the fuel filter when the engine is cooled. Do not spray any diesel to the
exhaust pipe.
Precautions
Use a new sealing ring when replacing the fuel filter. Do not fasten the filter too
tightly.
Replace the air filter once every 500 hours or when the indicator of the air filter turns
Frequency
red.
Service Standards Replace the cartridge with a clean new one of the same specification.
Frequency Replace the cooling water filter once every 500-hour operation (or quarterly).
Close the water inlet, and then remove the filter with a belt wrench.
Ensure that the new filter is equipped with a new sealing ring. Clean the contact
Operating
surface. Screw the new filter to the original position, and then further fasten it by two-
Procedure
third circle.
Open the water inlet.
Replace the original water filter with a new one and ensure that no leakage exists when
Service Standards
the diesel generator is running.
Replace the fuel filter when the engine is cooled to avoid scald.
Precautions Use a new sealing ring when replacing the water filter. Do not fasten the filter too
tightly.
Frequency Replace the cooling water once every 1000-hour operation (or annually).
Remove the upper cover from the water tank. Open the drain valve at the bottom of
Operating the water tank and ensure the water outlet is unblocked. Drain the cooling water,
Procedure wash the cooling system with clean water, and then close the drain valve.
Fill the water tank with cooling water, and then cover the water tank.
The cooling water level should be 5cm lower than the sealing surface of the sealing
Service Standards
cover.
Do not remove the upper cover from the water tank within 15 minutes upon shutdown
of the diesel generator.
Precautions
Do not fill the cooling system with any sea water, electrolyte, or other corrosive
matters.
Diesel Generator
Maintenance Record.xls